Related Manuals for SRAM RockShox ZEB Ultimate Flight Attendant
Summary of Contents for SRAM RockShox ZEB Ultimate Flight Attendant
- Page 1 2022-2023 ZEB, Lyrik, Pike Ultimate Flight Attendant SERVICE MANUAL GEN.0000000006531 Rev C © 2022 SRAM, LLC...
- Page 2 SAFETY FIRST! We care about YOU. Please, always wear your safety glasses and protective gloves when servicing RockShox products. Protect yourself! Wear your safety gear!
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Page 3: Table Of Contents
TABLE OF CONTENTS ROCKSHOX SERVICE ......................................4 PART PREPARATION ..............................................4 SERVICE PROCEDURES ..............................................4 MODEL CODE IDENTIFICATION ..........................................5 WARRANTY AND TRADEMARK ...........................................5 PARTS, TOOLS, AND SUPPLIES ..........................................6 RECOMMENDED SERVICE INTERVALS ........................................7 RECORD YOUR SETTINGS ............................................7 TORQUE VALUES ................................................7 OIL VOLUME AND LUBRICANT ...........................................8 EXPLODED VIEW .........................................9 2022-2023 (A2) ZEB ULTIMATE FLIGHT ATTENDANT ..................................9 2022-2023 (D1) LYRIK ULTIMATE FLIGHT ATTENDANT.................................. -
Page 4: Rockshox Service
Information contained in this publication is subject to change at any time without prior notice. Your product's appearance may differ from the pictures contained in this publication. For recycling and environmental compliance information, please visit: www.sram.com/en/company/about/environmental-policy-and-recycling. P a r t P r e p a r a t i o n Remove the component from the bicycle before service. -
Page 5: Model Code Identification
To identify the model code, locate the serial number on the product and enter it into the Search by Model Name or Serial Number field at www.sram.com/service. W a r r a n t y a n d T r a d e m a r k For SRAM Warranty information, visit: www.sram.com/warranty. For SRAM Trademark information, visit: www.sram.com/website-terms-of-use. Model Code Identification... -
Page 6: Parts, Tools, And Supplies
• Maxima PLUSH Dynamic Suspension Lube Heavy • Plastic mallet • Maxima PLUSH Dynamic Suspension Lube Light • Socket: 27 mm • SRAM Butter Grease • Socket wrench • RockShox Suspension Cleaner or isopropyl alcohol • Soft jaws (flat, aluminum) RockShox Tools •... -
Page 7: Recommended Service Intervals
Regular service is required to keep your RockShox product working at peak performance. Follow this maintenance schedule and install the service parts included in each service kit that corresponds with the Service Hours Interval recommendation below. For spare part kit contents and details, refer to the RockShox Spare Parts Catalog at www.sram.com/service. Service Hours Interval... -
Page 8: Oil Volume And Lubricant
Attendant Attendant Lube Lube Grease Lube Light Heavy Air Piston Light Pike Use ONLY RockShox, SRAM, and Maxima suspension oils/fluids and grease, unless otherwise specified. Use of any other lubricants can damage seals and decrease performance. Oil Volume and Lubricant... -
Page 9: Exploded View
E x p l o d e d V i e w 2 0 2 2 - 2 0 2 3 ( A 2 ) Z E B U l t i m a t e F l i g h t A t t e n d a n t Air Spring Assembly Steerer tube Compression Damper... -
Page 10: 2022-2023 (D1) Lyrik Ultimate Flight Attendant
2 0 2 2 - 2 0 2 3 ( D 1 ) L y r i k U l t i m a t e F l i g h t A t t e n d a n t Air Spring Assembly Steerer tube Compression Damper... -
Page 11: 2022-2023 (C1) Pike Ultimate Flight Attendant
2 0 2 2 - 2 0 2 3 ( C 1 ) P i k e U l t i m a t e F l i g h t A t t e n d a n t Air Spring Assembly Steerer tube Compression Damper... -
Page 12: Flight Attendant Control Module - Zeb, Lyrik, Pike
(−) Adjust button Menu button (+) Adjust button Flight Attendant Control Module Set screw AXS LED indicator Output driver (compression damper adjuster) AXS button SRAM battery Compression damper Battery latch Battery block SRAM battery Flight Attendant Control Module - ZEB, Lyrik, Pike... -
Page 13: Lower Leg Features - Zeb, Lyrik, Pike
L o w e r L e g F e a t u r e s - Z E B , L y r i k , P i k e Fender mount (x3) Pressure Relief Valve (x2) Bolt (x2) Dropout Adapter (x2) Lower Leg Features - ZEB, Lyrik, Pike... -
Page 14: Buttercups - Zeb, Lyrik, Pike
B u t t e r C u p s - Z E B , L y r i k , P i k e Air spring shaft Damper shaft Upper ButterCups housing Upper ButterCups housing Bushing Bushing Upper bumper O-ring ButterCups shaft end plate ButterCups shaft end plate... -
Page 15: Lower Leg Removal And Service
L o w e r L e g R e m o v a l a n d S e r v i c e 5 0 / 2 0 0 H o u r S e r v i c e L o w e r L e g R e m o v a l ZEB is pictured in this section. -
Page 16: 50 Hour Service
Place an oil pan beneath the fork to catch the draining oil. Place an oil pan beneath the fork to catch the draining oil. Loosen both bottom bolts 3 to 4 turns. Loosen both bottom bolts 3 to 4 turns. Spring side 5 mm Damper side... -
Page 17: Lower Leg Service
5 0 H o u r S e r v i c e L o w e r L e g S e r v i c e Remove the foam rings. Remove the foam rings. Pick Clean the foam rings. Clean the foam rings. - Page 18 Clean the inside and outside of the lower leg. Clean the inside and outside of the lower leg. Clean the wiper seals. Clean the wiper seals. RockShox Suspension Cleaner Dowel Install the foam rings under the wiper seals. Install the foam rings under the wiper seals. Confirm the foam rings are installed evenly and square in the space Confirm the foam rings are installed evenly and square in the space under the wiper seals and do not protrude out of the groove.
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Page 19: 200 Hour Service
2 0 0 H o u r S e r v i c e L o w e r L e g S e a l S e r v i c e Remove and discard the foam rings. Remove and discard the foam rings. Remove the outer wire springs from the dust wiper seals. - Page 20 Soak new foam rings in Maxima PLUSH Dynamic Suspension Lube Soak new foam rings in Maxima PLUSH Dynamic Suspension Lube Light. Light. Install the new foam rings into the lower leg. Install the new foam rings into the lower leg. Maxima PLUSH Dynamic Suspension Lube Light Remove the outer wire spring from each new dust wiper seal and set...
- Page 21 Install the outer wire springs. Install the outer wire springs. Lower Leg Seal Service...
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Page 22: Air Spring Service - Debonair
Spray RockShox Suspension Cleaner or isopropyl alcohol onto each part and clean with a clean lint-free shop towel. Apply SRAM Butter Grease to the new seals and o-rings. SRAM Butter Grease Remove the air spring top cap. Press down firmly when loosening the Remove the air spring top cap. - Page 23 Remove the retaining ring. Remove the retaining ring. ZEB: ZEB: Use your finger to guide the retaining ring and protect the air Use your finger to guide the retaining ring and protect the air spring shaft during removal. spring shaft during removal. NOTI CE Do not scratch the air spring shaft.
- Page 24 Push the shaft half way into the upper tube, then quickly and firmly pull Push the shaft half way into the upper tube, then quickly and firmly pull the shaft out to dislodge the seal head. the shaft out to dislodge the seal head. Remove the air spring assembly and seal head spacer from the upper Remove the air spring assembly and seal head spacer from the upper tube.
- Page 25 Clean the inside and outside of the upper tube. Clean the inside and outside of the upper tube. Inspect the inside and outside of the upper tube for damage. Inspect the inside and outside of the upper tube for damage. NOTI CE Scratches on the inside surface of the upper tube can cause air to leak.
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Page 26: Buttercups Removal - Air Spring Shaft
2 0 0 H o u r S e r v i c e B u t t e r C u p s R e m o v a l - A i r S p r i n g S h a f t Clamp the lower ButterCups housing into a vise with Reverb Vise Clamp the lower ButterCups housing into a vise with Reverb Vise Blocks or RockShox Rear Shock Vise Blocks on the wrench flats, with... - Page 27 Clamp the air shaft into the 10 mm slot of the RockShox Reverb Vise Clamp the air shaft into the 10 mm slot of the RockShox Reverb Vise Blocks or RockShox Rear Shock Vise Blocks with the air piston oriented Blocks or RockShox Rear Shock Vise Blocks with the air piston oriented downward.
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Page 28: Debonair+ - Air Spring Travel Change And Bottomless Tokens (Optional)
Bottomless Token kits. For part ordering information, please contact your local SRAM distributor or dealer. D e b o n A i r + - T r a v e l a n d B o t t o m l e s s T o k e n T u n i n g ( o p t i o n a l ) ZEB - 27.5"... -
Page 29: Debonair+ - Air Spring Travel Change And Bottomless Tokens (Optional)
Bottomless Token kits. For part ordering information, please contact your local SRAM distributor or dealer. 2 0 0 H o u r S e r v i c e A i r S p r i n g S e r v i c e A ZEB air spring assembly is pictured in this section. - Page 30 Remove the glide ring (upper), quad ring, and backup ring (lower) from Remove the glide ring (upper), quad ring, and backup ring (lower) from the air piston and discard them. the air piston and discard them. NOTI CE Do not scratch the air piston. Scratches will cause air to leak. Pick Clean the air piston.
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Page 31: Air Spring Assembly
Apply a liberal amount of grease to the air spring shaft. Apply a liberal amount of grease to the air spring shaft. SRAM Butter Grease Apply a thin layer of grease to the new top out bumper and Install it Apply a thin layer of grease to the new top out bumper and Install it onto the air spring shaft. - Page 32 Apply grease to the inner and outer seals on the Apply grease to the inner and outer seals on the new new seal head. seal head. SRAM Butter Grease SRAM Butter Grease SRAM Butter Grease Install the new seal head assembly onto the air shaft, flat side first.
- Page 33 Remove the grease from the inner shaft threads. Remove the grease from the inner shaft threads. Air Spring Assembly...
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Page 34: Buttercups Installation - Air Spring Shaft
Clean all grease from the threads. Clean all grease from the threads. SRAM Butter Grease Apply Loctite Threadlocker 2760 (red), or equivalent, to the first two to Apply Loctite Threadlocker 2760 (red), or equivalent, to the first two to three full threads of the ButterCups shaft end plate. - Page 35 Apply Loctite Threadlocker Blue 242, or equivalent, to three full outer Apply Loctite Threadlocker Blue 242, or equivalent, to three full outer threads on the lower ButterCups housing. threads on the lower ButterCups housing. Theadlocker Loctite 242 - Blue Install a new ButterCups bumper into the lower ButterCups housing, Install a new ButterCups bumper into the lower ButterCups housing, wide end first.
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Page 36: Air Spring Installation
A i r S p r i n g I n s t a l l a t i o n Apply a liberal amount of SRAM Butter grease evenly around the end Apply a liberal amount of SRAM Butter grease evenly around the end of a clean plastic dowel, approximately 150 mm from one end. - Page 37 SRAM Butter Grease Insert the seal head spacer into the upper tube, o-ring end first, and Insert the seal head spacer into the upper tube, o-ring end first, and seat it into the upper tube step until it stops.
- Page 38 ZEB: ZEB: Eyelet re Eyelet retaining rings have a sharper edged side and a rounder taining rings have a sharper edged side and a rounder edged side. Installing retaining rings with the sharper edged side edged side. Installing retaining rings with the sharper edged side facing the tool will allow for easier installation and removal.
- Page 39 Inject or pour Maxima PLUSH Dynamic Suspension Lube Heavy into Inject or pour Maxima PLUSH Dynamic Suspension Lube Heavy into the air spring upper tube. the air spring upper tube. 3 mL Maxima PLUSH Dynamic Suspension Lube Heavy Install the air spring top cap into the upper tube and tighten it. Press Install the air spring top cap into the upper tube and tighten it.
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Page 40: Damper Service
Remove the SRAM battery and install the battery block. Remove the SRAM battery and install the battery block. Install the battery cover on the SRAM battery and set it aside. Install the battery cover on the SRAM battery and set it aside. - Page 41 Loosen each Flight Attendant Control Module set screw. Loosen each Flight Attendant Control Module set screw. Do not remove the set screws. Do not remove the set screws. 2 mm 2 mm Carefully remove the Flight Attendant Control Module from the Carefully remove the Flight Attendant Control Module from the compression damper top cap.
- Page 42 Carefully remove the inner damper top cap / Control Module o-ring Carefully remove the inner damper top cap / Control Module o-ring seal. seal. NOTI CE Do not scratch the o-ring gland. Scratches can cause debris to enter the top cap under the Flight Attendant Control Module. Pick Clean the inside of the top cap and o-ring gland with a damp, clean Clean the inside of the top cap and o-ring gland with a damp, clean...
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Page 43: Damper Removal
2 0 0 H o u r S e r v i c e D a m p e r R e m o v a l Unthread the damper top cap and remove the damper assembly. Unthread the damper top cap and remove the damper assembly. NOTI CE The fork top caps are tightened to a high torque value. -
Page 44: Buttercups Removal - Damper Shaft
2 0 0 H o u r S e r v i c e B u t t e r C u p s R e m o v a l - D a m p e r S h a f t Clamp the lower ButterCups housing into a vise with Reverb Vise Clamp the lower ButterCups housing into a vise with Reverb Vise Blocks or RockShox Rear Shock Vise Blocks on the wrench flats, with... - Page 45 Clamp the damper shaft into the 10 mm slot of the RockShox Reverb Clamp the damper shaft into the 10 mm slot of the RockShox Reverb Vise Blocks or RockShox Rear Shock Vise Blocks with the damper Vise Blocks or RockShox Rear Shock Vise Blocks with the damper oriented downward.
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Page 46: Damper Service
2 0 0 H o u r S e r v i c e D a m p e r S e r v i c e Clamp the cartridge tube wrench flats in a vise with flat soft jaw inserts, Clamp the cartridge tube wrench flats in a vise with flat soft jaw inserts, rebound damper oriented upward. - Page 47 Apply grease to the new rebound damper seal head seals. Apply grease to the new rebound damper seal head seals. SRAM Butter Grease Install the new seal head onto the rebound damper shaft, threaded end Install the new seal head onto the rebound damper shaft, threaded end first, and slide it towards the piston until it stops.
- Page 48 Clamp the cartridge tube, on the bladder coupler wrench flats, back Clamp the cartridge tube, on the bladder coupler wrench flats, back into the vise. into the vise. Spray RockShox Suspension Cleaner or isopropyl alcohol into the Spray RockShox Suspension Cleaner or isopropyl alcohol into the cartridge tube.
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Page 49: Damper Assembly
2 0 0 H o u r S e r v i c e D a m p e r A s s e m b l y Clamp the cartridge tube wrench flats lightly into the vise and soft jaw Clamp the cartridge tube wrench flats lightly into the vise and soft jaw inserts. - Page 50 Insert the rebound damper piston slowly into the cartridge tube and Insert the rebound damper piston slowly into the cartridge tube and thread the seal head into the tube. thread the seal head into the tube. Tighten the seal head. Tighten the seal head.
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Page 51: Damper Bleed
2 0 0 H o u r S e r v i c e D a m p e r B l e e d Draw Maxima PLUSH 3wt suspension oil into a RockShox Bleed Draw Maxima PLUSH 3wt suspension oil into a RockShox Bleed Syringe until it is half full. - Page 52 Fully extend the rebound damper shaft. Push the syringe plunger Fully extend the rebound damper shaft. Push the syringe plunger down, then release the plunger. Allow the bladder to expand and down, then release the plunger. Allow the bladder to expand and retract until it stops in a resting position.
- Page 53 Cycle the rebound shaft a few times. Cycle the rebound shaft a few times. Remove the bottom bolt and clean the damper assembly. Remove the bottom bolt and clean the damper assembly. Damper Bleed...
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Page 54: Test Lockout Compression
2 0 0 H o u r S e r v i c e T e s t L o c k o u t C o m p r e s s i o n Use a Schrader valve core tool to rotate the keyed adjuster clockwise Use a Schrader valve core tool to rotate the keyed adjuster clockwise until it lightly contacts the stop point, to the locked out or firmest until it lightly contacts the stop point, to the locked out or firmest... -
Page 55: Buttercups Installation - Damper Shaft
Install a new upper ButterCups bumper, wide end first, onto the damper shaft. damper shaft. SRAM Butter Grease Apply Threadlocker Loctite 2760 (red), or equivalent, to the first three Apply Threadlocker Loctite 2760 (red), or equivalent, to the first three full threads on the end of the end plate. - Page 56 Install the lower ButterCups housing bumper into the lower ButterCups Install the lower ButterCups housing bumper into the lower ButterCups housing, wide side down, in alignment with the bolt. housing, wide side down, in alignment with the bolt. Apply Threadlocker Loctite 242 (blue), or equivalent, to three full outer Apply Threadlocker Loctite 242 (blue), or equivalent, to three full outer threads on the lower ButterCups housing.
- Page 57 Remove the damper shaft from the vise and vise blocks. Remove the damper shaft from the vise and vise blocks. Clamp the lower ButterCups housing into a vise with RockShox Vise Clamp the lower ButterCups housing into a vise with RockShox Vise Blocks on the wrench flats, damper oriented upward.
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Page 58: Damper Installation
Apply grease to a new o-ring and install it. Apply grease to a new o-ring and install it. SRAM Butter Grease Apply grease to a new inner top cap o-ring and install it. Apply grease to a new inner top cap o-ring and install it. - Page 59 Install the damper assembly into the damper side upper tube. Use Install the damper assembly into the damper side upper tube. Use your fingers to guide the damper and damper shaft into the upper tube your fingers to guide the damper and damper shaft into the upper tube without scratching the shaft.
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Page 60: Control Module Installation
2 0 0 H o u r S e r v i c e C o n t r o l M o d u l e I n s t a l l a t i o n The keyed ends of the Control Module output driver and the The keyed ends of the Control Module output driver and the compression damper adjuster must be aligned in the same orientation compression damper adjuster must be aligned in the same orientation... - Page 61 Position the back of the Control Module parallel with the crown, and Position the back of the Control Module parallel with the crown, and install the Control Module into the compression damper. install the Control Module into the compression damper. With the keyed ends of the Control Module output driver and With the keyed ends of the Control Module output driver and compression damper adjuster aligned, press the Control Module firmly...
- Page 62 Tighten each set screw evenly finger tight to center the Control Module Tighten each set screw evenly finger tight to center the Control Module position on the top cap. position on the top cap. Tighten each set screw to the specified torque. Tighten each set screw to the specified torque.
- Page 63 Check compression damper for proper function. Check compression damper for proper function. Press and hold the Menu button until the OPEN LED pulses red. Press and hold the Menu button until the OPEN LED pulses red. Press and release the ( Press and release the ( + + ) adjuster button until the LOCK LED pulses ) adjuster button until the LOCK LED pulses red.
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Page 64: 50/200 Hour Service
Apply grease to the inner surfaces of the dust wiper seals. Apply grease to the inner surfaces of the dust wiper seals. SRAM Butter Grease Install the lower leg assembly onto the upper tubes and slide it just Install the lower leg assembly onto the upper tubes and slide it just enough to engage the upper bushings with the upper tubes. - Page 65 Position the fork at an angle with the bolt holes oriented upward. Position the fork at an angle with the bolt holes oriented upward. Inject Maxima PLUSH Dynamic Suspension Lube Light into each lower Inject Maxima PLUSH Dynamic Suspension Lube Light into each lower leg through the bottom bolt holes.
- Page 66 200 Hour Service 200 Hour Service Remove the old crush washers from each bottom Remove the old crush washers from each bottom bolt. bolt. Hold the crush washer with needle nose pliers and unthread it from the Hold the crush washer with needle nose pliers and unthread it from the bolt by turning the bolt counter-clockwise.
- Page 67 Refer to your pre-service recorded rebound setting to adjust the Refer to your pre-service recorded rebound setting to adjust the rebound damping. rebound damping. SRAM Butter Grease 2.5 mm 3.3 N∙m (29 in-lb) Refer to your pre-service recorded settings, or use the air chart on the Refer to your pre-service recorded settings, or use the air chart on the fork's lower leg, and pressurize the air spring.
- Page 68 ASIAN HEADQUARTERS WORLD HEADQUARTERS EUROPEAN HEADQUARTERS SRAM Taiwan SRAM LLC SRAM Europe No. 1598-8 Chung Shan Road 1000 W. Fulton Market, 4th Floor Paasbosweg 14-16 Shen Kang Hsiang, Taichung City Chicago, Illinois 60607 3862ZS Nijkerk Taiwan R.O.C. U.S.A. The Netherlands...
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